A mathematical model for a Two-Span Web Roller machine is defined in order to facilitate motion planning, motion tracking and state observer design for tracking web tension and web velocity. Differential Flatness is utilized to create reference trajectories that are tracked with a high convergence rate. Flatness also allows for nominal input torque generation without integration. Constraints on the inputs are satisfied through the motion planning phase. A partial state feedback linearization is performed and an exponential tracking dynamic feedback controller is defined. An exponential Kalman-related tension observer is also defined with semi-optimal gain formulation. The observer takes advantage of the bilinearity of the dynamics up to additive output nonlinearity. The closed-loop system is simulated in MatLab with comparisons to reference trajectories previously employed in literature. The importance of proper motion planning is demonstrated by producing excellent performance compared with existing tracking and tension observing methods.

A mathematical model for a Two-Span Web Roller machine is defined in order to facilitate motion planning, motion tracking and state observer design for tracking web tension and web velocity. Differential Flatness is utilized to create reference trajectories that are tracked with a high convergence rate. Flatness also allows for nominal input torque generation without integration. Constraints on the inputs are satisfied through the motion planning phase. A partial state feedback linearization is performed and an exponential tracking dynamic feedback controller is defined. An exponential Kalman-related tension observer is also defined with semi-optimal gain formulation. The observer takes advantage of the bilinearity of the dynamics up to additive output nonlinearity. The closed-loop system is simulated in MatLab with comparisons to reference trajectories previously employed in literature. The importance of proper motion planning is demonstrated by producing excellent performance compared with existing tracking and tension observing methods.